KR19980019463A - Flexible Foam Sheet Production Process Coating of Far Infrared Rays Radiated Ocher and Stone Power - Google Patents

Abstract

The present invention is a method for producing a flexible foam sheet as a skin material or liner for building interior materials, furniture, and mats coated with clay powder capable of emitting far infrared rays such as loess. Conventional products do not exhibit the inherent function of ocher by confining it in a resin. The structure of this invention mix | blends an oleic acid type foaming agent, a dispersing agent, and a foam stabilizer with water-soluble resins, such as an acrylic resin, a polyurethane, and a synthetic rubber, and the loess which can radiate far infrared rays to 60-95 weight% of this mixed water-soluble resin raw material, It is a method of mixing 5 to 40% by weight of fillers such as clay and gangue powder, and coating the mixture while injecting air into the fiber member, and then drying at 100 to 200 ° C. within about 10 minutes to foam at a rate of 1.5 times or more. . A high density porous breathable open cell in which ocher and the like are uniformly distributed is obtained.

Description

Method of manufacturing flexible foam sheet coated with earth powder of far infrared radiation

The present invention provides a method for manufacturing a flexible foam sheet as a coating material or liner for building interior materials, furniture, mats and the like, which is coated with a resin and foamed with a clay powder capable of emitting far infrared rays such as loess ( Flexible Foam Sheet Production Process Coating of Far Infrared Rays Radiated Ocher and Stone Powder).

Since similarities, human civilization has been kept with the soil, and the beginning of all life cannot be thought of separately from the soil. However, as industrialization accelerated, road pavement increased, and soil was considered unnecessary dust. Recently, as the raw material of far-infrared radiation ceramics has been used, research on soil has been derived.

Currently, the cases of using ocher, elvan, and clay to commercialize flooring and wallpaper are increasing rapidly. Most of them are formed by mixing ocher with resin raw materials or cement mortar. In the conventional flexible ocher mat manufacturing method, two sheets of non-breathable polyvinyl chloride (PVC) film are overlapped with each other by high-frequency bonding, and then, ocher, elvan, and clay powder are inserted therebetween.

However, in the case of molding by mixing ocher in the resin raw material as described above, the ocher is imprisoned in the resin or latex does not exhibit the inherent function of the ocher. Such ocher-based resin moldings are generally thick and hard and can be used as flooring or walling materials, but could not be used as skin or liners such as flexible mats or furniture. In the case of cement mortar using ocher, of course, there are limitations as mentioned above.

In the case of the ocher mat in which the ocher is inserted into the polyvinyl chloride film in the above-described conventional art, the ocher has flexibility, but since the ocher is confined in the film, the inherent function of the ocher, that is, antibacterial function, air purification function, humidity control function, etc. Not only can this be unacceptable, but the waterproofness of the polyvinyl chloride film can cause sweating when used as a summer mat. In addition, the manufacturing process of the ocher mat has a disadvantage that the work is very slow, workability and productivity is very low.

An object of the present invention is to maintain the inherent function of the loess having far-infrared radiation, antimicrobial and the like as much as possible, and to be composed of a thin sheet having flexibility to be used as a skin material or liner of various interior materials, wallpaper, furniture, mats, etc. In particular, to be applied to the heating mat.

1 is an exemplary air foaming process of the embodiment of the present invention.

Figure 2 is a far infrared radiation energy comparison diagram of the sample and the black body obtained by the present invention.

3 is a far-infrared emissivity curve diagram of a sample obtained by the present invention.

Explanation of symbols for main parts of the drawings

1: fabric, 2: dryer, 3: binder, 4: knife, 5: air compressor, 6: flow furnace

In order to achieve the above object, the present invention mixes an oleic acid-based blowing agent, a dispersing agent and a foaming agent to at least one or more water-soluble resins selected from acrylic resins, polyurethanes and synthetic rubbers, 60 to 95% by weight of the blended water-soluble resin raw material 5% to 40% by weight of at least one filler selected from loess, white clay, and elvan powder, which can emit far-infrared rays, is mixed with%, and the mixture is coated while injecting air into the fiber member, and then about 10 to 100 to 200 ° C. It is characterized by a method of drying within a minute and foaming at a rate of 1.5 times or more.

The reason why the resin is limited to water solubility is largely for the purpose of suppressing the generation of waste water in the environment. Therefore, the same effect can be obtained technically even when using the water-insoluble resin of the same series as the water-soluble resin illustrated above. These water-soluble resins may be mixed with each other, but are preferably limited to one kind. Examples of synthetic rubbers include butadiene styrene copolymer (SBR) and butadiene acrylonitrile (NBR).

The oleic acid-based blowing agent is a kind of reactive inorganic foaming agent and has the most suitable properties for obtaining the foam sheet of the present invention compared to other inorganic foaming agents, such as sodium bicarbonate and ammonium carbonate. Azodicarbon amide (ADCA), azobis isobutyronitrile (AIBN), and dinitroso pentamethylene tetramine (DPT), which are a type of organic foaming agent, generate carbon dioxide and nitrogen gas during dry foaming. The foam surface is very irregular and smooth foam coating is difficult.

In the oleic acid-based foaming agent of the present invention, when air-foamed using a polycarboxylic acid soda-based dispersing agent and a polysiloxane foam stabilizer, it was found by experiment that the uniformity of the degree of foaming during drying is superior to that of other foaming agents. At the time of addition of the blowing agent, 5 to 20% by weight of a water repellent may be added. Adding a water repellent improves water repellency and breathability.

Ocher, loam and elvan powder are finely divided fillers in a dry state and may be mixed with each other, but the use of one or more of them does not affect the effect to be obtained in the present invention.

The mixing ratio of such a filler and the above-mentioned water-soluble resin raw material to 5 to 40% by weight to 60 to 95% by weight is indicative of a range of optimum values for increasing the uniformity of foaming, far-infrared emissivity, and work efficiency. For example, when the filler is 5 wt% or less, the far-infrared emissivity is significantly lowered, and the filler has a great influence on the inherent function of the filler, and when it is 40 wt% or more, the water of the water-soluble resin raw material is excessively excessive due to the hydrophilicity of the filler. As it absorbs, it is very difficult to coat the mixture on the fiber member. Among the fillers, in the case of elvan powder, the degree of coagulation at the time of mixing is lower than that of yellow clay or white clay, and thus, about 50% by weight may be added.

The fiber member includes natural fibers and various artificial fibers such as regenerated artificial fibers, synthetic fibers, inorganic fibers, composite fibers, and functional fibers, and is a member of a substrate present in the form of a woven fabric, a nonwoven fabric, or a combination thereof. In order to coat the mixture of the water-soluble resin raw material and the filler on such a fiber member, it is necessary to artificially inject air into the mixture. This allows the filler to meet the required foaming ratio of 1.5 times or more while avoiding all trapping in the resin in the foamed open cell. The method of injecting air into the mixture is through a nozzle-type flow path while applying a constant air pressure to the mixture.

Drying conditions applied after the coating of the mixture on the surface or both surfaces of the fiber member, that is to dry within about 10 minutes at 100 ~ 200 ℃ is one of the important conditions in the present invention, foaming at a rate of 1.5 times or more of the coating thickness Although it is also a condition for making the filler, it is essential to maintain the uniformity of the foam and the flexible cell structure and impart durability while preventing the filler from being trapped in the resin in the foamed open cell. Failure to meet the drying conditions results in the foam becoming brittle, unfoamed, or unable to maintain the shape of the cell structure continuously.

The foamed sheet obtained by the present invention has a breathable function due to a vulcanized morphology, that is, a filler such as loess because of open cells may be subjected to external moisture, oxygen, temperature, optical or biochemical effects, etc. The foam is relatively thin layered on the fibrous member and thus has flexibility and cushioning properties. The combination components of the resin raw material and the blowing agent have water resistance, acid resistance, and alkali resistance, and because the size of the filler and the cell is also given in a very fine state, it is possible to maintain the above characteristics while ensuring breathability. In particular, in the case of selecting the water-soluble resin as the acrylic resin, it was found that the collection force of the fine particles of the filler, such as loess, excellent in its properties. The emissivity of far-infrared is mentioned in the experiments on the foam sheet obtained by the following example, but appears to be about 90% or more. In addition, because of its porous structure, the adsorption power results in an odor adsorption rate of 85% or more. Since the foam has an anion molecular structure, it has an antibacterial effect of decomposing the anionic outer wall structure of bacteria by electrostatic force, and the silicon dioxide structure in the containing chemical component generates fresh dissolved oxygen (O ₂ ).

Hereinafter, an embodiment for obtaining a general-purpose foam sheet which can be used as a surface paper of a wallpaper or a heating mat, a liner of furniture or building interior materials is described.

A water-soluble acrylic resin, an oleic acid-based blowing agent, a polycarbonate-based dispersing agent, and a polysiloxane foaming agent are blended at the same level as the amount of the raw material blended at the time of foaming the resin using a conventional reactive foaming agent. 65 wt% of the water-soluble resin raw material thus blended was mixed with 25 wt% of dried ocher fine powder, and 10 wt% of a water repellent was added to the mixture and mixed.

Thereafter, the mixture is subjected to air foaming on the surface of the fabric by the process as shown in FIG. 1. That is, the fabric 1 is conveyed into the hot air chamber type dryer 2 by a belt, and at the same time, the binder 3, which is a mixture containing air bubbles, is placed in the conveying path of the fabric so as to have a predetermined thickness by using the knife 4. Coating while cutting. At this time, the coated thickness was 1mm. The coating thickness is suitably 1 to 2 mm, and the knife 4 means a roll coater or a knife coater.

The bubbles contained in the binder 3 are given by the air compressor 5. That is, a nozzle-type flow path 6 having two inlets and one outlet is installed in the air compressor 5 which is set at a constant pressure, and a binder is introduced into one inlet of the flow path 6 and the other Blow air into the inlet. Then, a binder 3 having a myriad of bubbles, accompanied by a state change such as surface activation, exits the outlet and is supplied onto the fabric 1 on one side of the knife 4.

The dryer 2 heats the coated surface at 100 to 200 ° C., and if the heating time is maintained within about 10 minutes, the dryer 2 is uniformly foamed to a thickness of about 1.5 mm.

The following is an enlarged photograph 1000 times of the cell cross section of the foam sheet obtained by the Example.

The photograph was taken with a scanning electronic microscope (SEM) with an output voltage of 20kv. It can be seen that the small bulk (ocher) fine particles and the cell pores of a larger or similar size than those of the filler fine particles are dense (high density) and uniformly distributed in contact with or adjacent to each other. have.

The finally obtained foam sheet sample was requested by KICM (Issuance No .: FIR-126) and far-infrared radiation measurement was performed. The measurement conditions are 40 ° C. and a black body using the FT-IR Spectrometer. As a result, the emissivity (5-20 µm) was 0.90, and the radiation energy (W / m 2 · µm, 40 ° C) was 3.62 × 10 ² . Figure 2 shows the radiation energy comparison diagram, Figure 3 shows the emissivity curve.

The following is a result of the antimicrobial test by requesting the foam sheet sample obtained by the present invention to the test institute (issuance number: FAB-029). The test method was according to KICM-FIR-1002, and the strains used were Escherichia coli (Escherichia coll ATCC 25922) and Pseudomonas aeruginosa ATCC 15442.

Test Items Sample classification Initial concentration (dog / ml) After 6 hours (dog / ml) After 24 hours (dog / ml) Bacterial Reduction (%) Antibacterial test by E. coli Blank 270 420 640 - Sample of the Invention 270 176 69 74.4 Antibacterial test by Pseudomonas aeruginosa Blank 440 630 980 - Sample of the Invention 440 290 141 68.0

Untreated in Table 1 was measured without the sample, the number of bacteria on the medium is calculated by multiplying the dilution factor. The test result showed excellent bacterial reduction rate of E. coli 74.4% and Pseudomonas aeruginosa 68.0%.

The present invention can be used as a skin material or liner such as flooring, architectural interior materials such as wallpaper, furniture, medical heating mats, electric blankets and the like. It is possible to implement a breathable ocher in the optical and biological environment, such as air permeability, humidity, temperature maintenance, etc. to create a natural-friendly indoor environment that is beneficial to the human body. And a thin foamable fiber sheet can be obtained which gives flexibility and a cushioning feeling, and since it has the outstanding effect also in water resistance, acid resistance, and alkali resistance, the application range becomes very wide.

In addition, since a high density porous foam sheet having a high emissivity of far infrared rays is obtained, when used as a residential device, the heat transfer effect of the heating body is increased while reducing heat loss in the room as well as activating bioenergy, antibacterial action, and air purification (deodorization).

Claims (5)

Oleic acid-based blowing agent, dispersant and foam stabilizer are blended with at least one resin selected from acrylic resins, polyurethanes, and synthetic rubbers, and the filler is composed of earth powder capable of spinning far-infrared rays in 60 to 95% by weight of the blended resin raw material. A method of manufacturing a flexible foam sheet comprising 5 to 40% by weight, which is coated while injecting the mixture into the fiber member, followed by drying at 100 to 200 ° C. within about 10 minutes and foaming at a rate of 1.5 times or more. The method of claim 1, wherein the resin is water-soluble. The method of claim 1, wherein the filler is at least one or more selected from loess, clay, and elvan powder. The method of manufacturing a flexible foam sheet according to claim 1, wherein 5 to 20% by weight of a water repellent is added to the resin raw material. The method of claim 2, wherein the synthetic rubber is butadiene styrene copolymer (SBR) or butadiene acrylonitrile (NBR).